Available Online at http://www.recentscientific.

com
International Journal
of Recent Scientific
International Journal of Recent Scientific Research Research
Vol. 6, Issue, 6, pp.4472-4476, June, 2015
ISSN: 0976-3031
RESEARCH ARTICLE
DESIGN AND MANUFACTURING OF PNEUMATIC PIPE BENDING MACHINE
1Vikash Patial, 2Kiran Choudhary, 3Prathamesh Rane, 4Vijay Inamdar
and 5D.A Wagholikar
Department of Mechanical Engineering, Pimpri Chinchwad College of Engineering, Pune University,
Pune, India

ARTICLE INFO ABSTRACT

Article History:
th
Received 5 , May, 2015
Received in revised form 12th,
May, 2015
Accepted 6th, June, 2015
Published online 28th,
June, 2015
Key words:
Drosophila, Diversity,
Occurrence constancy method,
Simpson index
In line with the growth in the recent technologies, there is large opportunity present in the piping sector.
As the part of the piping industry the demand of the customer being changes day by day. The manual pipe
bending machines are not able to fulfill the raising demands of the market in quality, quantity as well as
cost prospective.
Particularly in this machine, we have used the compressed air to perform the bending operation. This
makes the machine or the process much more efficient over the manual operated bending machine. Radius
of the bend can be obtained within the limits of this machine. The machine is very useful for the
Aluminum & copper pipes.
The name of the machine explains the concept of the machine. The rollers of the radius equal to the radius
of the pipe are placed at the location suitable to the radius of the bend to be obtained. The horn which
having the radius equal to the radius of the bend is connected to the piston of the pneumatic cylinder. The
required force is applied on the horn by the compressed air through the cylinder.
The machine is designed to bend a pipe of aluminum, MS and copper type of metallurgical grade.
The aluminium and copper pipe upto 22 mm OD and 1.5 mm thickness and MS pipe upto 20 mm OD and
0.5mm thickness has ben designed by this machine.

Copyright © Vikash Patial et al., This is an open-access article distributed under the terms of the Creative Commons Attribution License,
which permits unrestricted use, distribution and reproduction in any medium, provided the original work is properly cited.

INTRODUCTION
Pipe bends are critical components in piping systems. In the
manufacturing process of pipe bends it is difficult to avoid
thickening on the intrados and thinning on the extrados. The
cross section of the bend also becomes non circular due to
bending process. The acceptability of pipe bends is based on
the induced level of these shape imperfections.
Ovality and thinning are the shape imperfections considered for
the analysis. It is observed that thinning and ovality are to be
taken into account together to decide the acceptability of these
bends. The possible flexibility that can be introduced in the
selection of ovality and thinning limits of pipe bends to reduce
rejection has been suggested.
forming process of pipe bends, the outer fibre of the pipe bends
thin down, which leads to a phenomenon known as thinning
Pipe Bend cross section
The following assumptions are made in the analysis: Linear
behavior, homogeneous isotropic material, and steady static
state loading. The effects of the following are not considered in
the present evaluation: Bourdon’s effect, external pressure,
external forces, external moments, centrifugal forces due to
change of fluid flow direction, effects of friction between the
pipe inside fluid and the pipe bend inner surface, fluid
turbulence, interfaces between the straight pipe and pipe bend,
tolerances and deviations of the straight pipe before fabricating
into pipe bend and pipe bend surface roughness.

Pipe bends are used extensively in power plants to convey
fluids and to change the direction of the fluids flowing inside
the pipes. Bending of pipes with circular cross section is of
considerable importance in the manufacture of boilers and the
construction of pipe lines. Although the selection of a pipe
bend manufacturing process for a specific case is influenced by
several factors the most frequent methods of bending of pipes
are bending with a mandrel and without a mandrel. During
The cross section of a pipe bend is assumed to become a
perfect ellipse after bending as shown in the figure.
Design Methodology
Design consists of application of scientific principles, technical
information and imagination for development of new or
improvised machine or mechanism to perform a specific
function with maximum economy & efficiency.

*Corresponding author: Vikash Patial

Department of Mechanical Engineering, Pimpri Chinchwad College of Engineering, Pune University, Pune, India
 Vikash Patial et al., Design And Manufacturing Of Pneumatic Pipe Bending Machine
Figure 1 Pipe bend cross section before and after bending
Hence a careful design approach has to be adopted. The total
design work, has been split up into two parts
 System design
 Mechanical Design.
System design mainly concerns the various physical constraints
and ergonomics, space requirements, arrangement of various
components on main frame at system, man + machine
interactions, No. of controls, position of controls, working
environment of machine, chances of failure, safety measures to
be provided, servicing aids, ease of maintenance, scope of
improvement, weight of machine from ground level, total
weight of machine and a lot more.
In mechanical design the components are listed down and
stored on the basis of their procurement, design in two
categories namely,
 Designed Parts
 Parts to be purchased
Calculations for Plastic and Elastic deformation
Calculations within Elastic Limit
By using Flexural formula:
Poisson’s ratio= 0.27-0.30 , E=210 GPa
y= distance of center to pt. of maximum stress.
Outer diameter of pipe= 20 mm, Inner diameter of pipe= 19
mm
Thickness of pipe= 0.5 mm
Mb = w/2*l/2
And also, Ixx = π/64 *(do4 -di4). Therefore , Ixx = 1456.864 mm4
Thus putting above values in flexural formula,
We get value of w = 699.294 N
Calculations for plastic deformation
Factor required by pipe to bend from static to plastic region is
given by Ksp = (Fp /w)
Assuming, Ksp = 1.58
This means that 1.583 times the static force is required to bend
a pipe in plastic zone.
Therefore, force required = Ksp * w = 1.58 * 699.29
Fp = 1107.216 N
Now, let us find the deflection of pipe under static condition for
load w=699.294 N
Deflection of pipe
For simply supported beam at center point load,
0
Simply supported beam
Deflection at center is given by, y = wl3 /48 EI
y = (699.294*(300)3)/(48 * 210000*1456.864) mm
y = 1.2850 mm
Now, roller and pipe will be in contact.
Therefore, friction will occur between them, coefficient of
friction is 0.16
Fr = 0.16* Fp i.e. Fr = 177.154 N
Also, the friction will occur between piston and inner surface
of cylinder.
Rubber O ring and UPVC are in contact
Therefore Fp’ = 0.15* 1107.216 i.e. Fp’ = 166.082 N
Thus, total frictional force, Ff = Fr + Fp’
Therefore, Ff = 343.236 N
Total force required along with frictional force to bend a pipe
of mild steel (OD= 20 mm and t= 0.5 mm)
Total force required, FT = Ff + Fp
FT = 343.236+1107.216=1450.452 N
Thus, total force required to bend a pipe is 1450.452 N
Design of pneumatic cylinder
P= FT / A , di = ((4* FT )/pπ)1/2
Selecting pressure not exceeding than 12 kg f/cm2
Nominal diameter= 40 mm
Outer Diameter= 50 mm
Theoretical Displacement to be travelled by Horn
The displacement travelled by the horn from roller center line
up to bend angle of various angles of various degrees without
considering spring back effect can be calculated as follows
4473 | P a g e
 International Journal of Recent Scientific Research Vol. 6, Issue, 6, pp.4472-4476, June, 2015

θU = bend angle after the occurrence of spring back.

θL = bend angle before spring back has occurred
RL & ML = bend radius and bending moment
E & I = Modulus of elasticity and area moment of
inertia.

Spring back for Aluminium is calculated using following

formula:

Spring back angle(dθ ) = (0.00791*θ) + 0.4664

Where θ = bend angle required

Figure 2 Theoretical distance travelled by the horn

tan45= y/150 i.e. y= 150 mm

Table 1 Theoretical displacement travelled by the horn

Angle (θ) Displacement ( y ) , mm
90 150
95 137.44
100 125.86
105 115.09
110 105.03
115 95.56
120 86.60
125 78.08
130 69.94
135 62.13
140 54.59 Figure 2 Spring back before and after bending
145 47.29
150 40.192 Table 2 Spring back angle for Al
155 33.254
160 26.449 Angle (θ) Spring back angle
165 19.747 90 1.178
170 13.123 95 1.217
100 1.257
Spring back effect 105 1.296
110 1.336
115 1.376
In bending after the applied force is withdrawn the metal tries 120 1.415
to resume its original position causing a decrease in bend angle. 125 1.455
Such a metal movement is called as spring back phenomenon. 130 1 1.494
135 1.534
140 1.573
It is caused by the elastic stresses remaining in the bend area. 145 1.613
After the bending pressure on metal is released the elastic 150 1.652
stresses are also released and causes metal movement. Spring 155 1.692
back varies from ½ to 5 degree in steel and ½ to 3 degrees in
Table 3 spring back angle for MS
aluminium.
Angle (θ) Actual bend angle obtained Spring back angle
The elastic stresses remaining in the bend area after bending 90 91.23 1.23
pressure is released will cause a slight decrease in the bend 95 96.29 1.29
100 101.36 1.36
angle.
105 106.43 1.43
110 111.49 1.49
Metal movement in this type is known as spring back, as shown 115 116.56 1.56
in figure 1. The magnitude of the movement will vary 120 121.63 1.63
according to the material type, thickness and hardness. A larger 125 126.70 1.7
bend radius will also cause grater spring back. 130 131.76 1.76
135 136.83 1.83
140 141.90 1.9
The spring back increases with increase in tensile strength, 145 146.97 1.97
bend radius, bend angle. 150 152.04 2.04
155 157.10 2.1
Spring back is calculated for mild steel as:
θU = θL * (1- (RL ML / E I )) From the above graph it is clear that as bending angle increases
where , spring back angle also increases irrespective of material.

4474 | P a g e
 Vikash Patial et al., Design And Manufacturing Of Pneumatic Pipe Bending Machine

Figure 3 Comparison between spring back angle and bending angle

Figure 6 Deflection in pipe upto yield poin for MS

Figure 4 Comparison between spring back angle and bending velocity

From the above graph it is also clear that as bending velocity

increases spring back angle increases gradually and then
becomes lesser as compare to earlier. Figure 7 Stresses in pipe under working condition

CONCLUSION
ANSYS RESULTS
1. The testing was done on aluminium pipe of 20mm OD
and 1.5mm thickness and MS pipe pipe of 1
inch(25.4mm) and 0.5mm thickness.
2. The trial for aluminium pipe was done by filling fine
sand to reduce the pipe thickness at bent portion.
3. The aluminium pipe of 20mm OD and 1.5mm thickness
was made bend successfully upto 70 degress by
application of 7 bar pressure and control of compressed
air by flow control valve.
4. Similarly MS pipe of 1 inch (25.4 mm OD) and 0.5mm
thickness was bend upto 60 degress by application of 5
bar pressure and control of compressed air by flow
control valve.
5. During the testing the sand was filled in both the
metallurgical grade of pipes to prevent fracture of pipe
and reduces the induced stesses beyond the ultimate
point and testing was performed.
6. Also during the testing the effect of spring back angle
was considered for both the metallurgical grades of
pipe.
Figure 5 Stresses in pipe upto yield point for MS

4475 | P a g e
 International Journal of Recent Scientific Research Vol. 6, Issue, 6, pp.4472-4476, June, 2015

7. It was observed that as bending angle increases spring
back angle also increases for a particular metallurgical
grade of pipe.
8. It was also observed that as brittleness of material
increases spring back angle also increases that is spring
back angle for MS was observed more as compare to
aluminium for a particular bend angle.
References
Reference Papers
Spring back law of tube upon bending by “Ll Heng, SHI Kai-
peng, YANG He,TIAN Yu-li”
Prediction of spring back in tube bending process based on
forming parameters by “Levent Sozen, Mehmet A. Guler ,
Recep M. Gorguluarslan, Engin M. Kaplan”
Reference Books
• Production technology – r k jain
• Machine design - r s khurmi
• Design data - p s g
• Industrial fluid power – d s pavaskar
• Metal forming processes – g r nagpal
• press tools design and construction – p s joshi

How to cite this article:

Vikash Patial et al., Design And Manufacturing Of Pneumatic Pipe Bending Machine. International Journal of Recent
Scientific Research Vol. 6, Issue, 6, pp.4472-4476, June, 2015

*******

4476 | P a g e